As oil and gas companies move to more unpredictable and complex offshore drilling environments, a focus is given on safety and creating a risk-free environment. Offshore drilling possesses hazards like kick, loss circulation, and sticking of pipe due to differential pressure, which can lead to pipe twisting. These can have a significant impact on non-productive drilling time. This analyses the importance of the managed pressure drilling (MPD) market for safe and cost-effective drilling.
Key drivers and restraints are discussed along with their impact in the short term and long term. The MPD systems market size is based upon the number of key industry players. The base year for the study is 2014 with a forecast period from 2015 to 2020.
Despite this growth, conventional drilling includes hazards like influx of the drilling fluid due to the loss of circulation and the sticking of pipe due to differential pressure (which could lead to twisting of the pipe), these hazards accounts to the non-productive time (NPT).
Managed pressure drilling (MPD) is an emerging drilling technology that can be a reactive and proactive method, which helps to control most of the drilling hazards by making minimum modification to the rig setup.
Different types of MPD are:
– Constant Bottom Hole Pressure (CBHP);
– Mud Cap Drilling (MCD);
– Dual Gradient Drilling (DGD);
– Return Flow Control (RFC).
Managed pressure drilling system of Reform Energy Services
Reform Energy Services is an international company specializing in Underbalanced Drilling, Managed Pressure Drilling, and Production Testing/Flowback Services.
“Managed Pressure Drilling, MPD, is an adaptive process used to precisely control the annular profile throughout the well bore. The objectives are to ascertain the down‐hole pressure environment limits and to manage the annular hydraulic pressure profile accordingly. This may include the control of back pressure by using a closed and pressurized mud return system, an annular back pressure pump or other such mechanical devices. MPD is intended to avoid continuous influx of formation to surface.”
MPD involves drilling utilizing a controlled environment that proactively manipulates the annular pressure profile by increasing or decreasing back pressure at the surface. The surface pressure can be managed by the incorporation of specialized MPD equipment, such as Rotating Control Flow Diverter (RFCD), MPD choke manifold, and Annular Back Pressure (ABP) pumps.
MPD techniques allow control the annular pressures dynamically, enabling drilling in areas where otherwise it would not be economically or technically attainable with conventional drilling techniques.
The main reasons for considering MPD techniques are shown below:
1.To enable drilling;
2.Maximize production through minimizing reservoir impairment;
3.Reservoir characterization;
4.Minimizing NPT;
5.Reduce drilling cost.
This technique resolves many traditional drilling problems and hazards. Some of the benefits include:
1.Elimination of a casing string;
2.Decrease probability of differential sticking;
3.Instantaneous reduction/increase in bottom hole pressure (Well control);
4.Reduce probability of lost returns;
5.Improve ROP;
6.Decrease formation damage;
7.Lower probability of formation stability problems;
8.Mitigate the problems associated with ballooning;
9.Improve hole cleaning;
10.Increase the length of the hole that can be drilled;
11.Kick detection and control;
12.Reservoir characterization.
Technological advantages and cost saving features of our equipment
Reform has taken great pains in designing its own equipment with many innovative features to save time and money, and enhance safety. The following are some of the key differences versus other equipment on the market
MPD semi-automatic manifold with Integrated Control System: Our MPD manifolds have been designed to automatically maintain the annulus surface back pressure during drilling operations within a predetermined pressure operating window by using a set of two tight shut off capable actuated full bore drilling chokes. These are controlled by a PLC based control system to maintain the selected set point pressure using an HMI interface panel for operator input of required settings and for displaying control system output parameters.
Higher pressure separators: Most MPD separators have a working pressure of less than 250 psi. Reform Energy Service’s MPD units have a working pressure separator of 500 psi. This translates to less erosion on the equipment and lower costs to you for downtime.
Multiple inlets with sleeves: Most separators have only one inlet, which means when it erodes, it causes immediate downtime. Our MPD units have multiple inlets, so flow can be dispersed. We also sleeve the inlets to reduce downtime and cost (sleeves are inexpensive and relatively easy to replace). No heat treatment or radiography is required.
Rotating Flow Control Diverter: Our RFCDs are one of the industries newest passive rotating control heads, designed in accordance with API Specification RCD-16. These RFCDs have several unique patent pending design components intended to make this RFCD one of the safest and most efficient available.
MPD PACKAGES
Rotating Flow Control Diverter
Been considered the main enabling piece of equipment for MPD, our RCDs will provide the necessary seal between the wellbore and the atmosphere, allowing drilling when gas and fluid influxes are encountered.
MPD Choke Manifod
As part of the primary barrier for well control during MPD operations, our SemiAutomated control choke system will provide a reliable way to maintain the bottom hole pressure required for drilling.
Mud/Gas Separator
It allows to capture and separate large volume of free gas within the drilling fluid. If there is a “KICK” situation, this vessel separates the mud and the gas, diverting the fluid back to the pits/tanks and the gas is vented to a flare.
High Pressure Four Phase Separator
In a kick situation, our high pressure fourphase separator will allow to circulate the influxes in a safe and controlled manner, avoiding the need of shutting the well. Complete with dual geological sample catchers, fluid handling equipment for fluid and solids transfer, and automatic dump valves.
Closed Top Cascading 400 bbl Storage Tanks
When drilling in a closed loop sour environment, our closed top cascading 400 bbl storage tanks will enhance the separation and subsequent removal of any poisonous gas from the system. Additionally, they will act as a retention vessel generating a cleaner and solid free drilling fluid.
Nitrogen Generation and Compression Equipment
Some operations may require lighten the drilling fluid. Nitrogen generation and the air compression packages will be provided by a third party.
Ammonia Scrubber
The ammonia scrubber will remove or neutralize the substances considered harmful to the environment.
Flare Stacks
Our flare stacks offer zero ground disturbance and eliminates the need for anchors, and use a Tornado pilot system, which substantially reduces the consumption of propane. This saves substantial time and cost.
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